Molded Footwear Upper And Method Of Making Same

ABSTRACT

A method for manufacturing an upper for an article of footwear includes: forming a foam layer; forming a preliminary upper by laminating an outer layer, an inner layer, and the foam layer intermediate to the outer layer and the inner layer; and molding the preliminary upper to a shape having: a contour to substantially fit at least a portion of a foot to provide at least a portion of an upper for an article of footwear.

BACKGROUND OF THE INVENTION

1. Field of the Invention

Embodiments of the present invention generally relate to footwear, andmore particularly relate to a molded upper for an article of footwearand related methods of making the same.

2. Background Art

Shoe manufacture is a labor intensive process. The typical shoemanufacturing process encompasses the steps of cutting the uppermaterial, reducing the thickness of the joining edges (“skiving”),reducing the thickness of the upper pieces (“splitting”), cementing theinterlining to the upper pieces (“interlining”), forming the eyelets,stitching the upper pieces together, shaping the upper over a last(“lasting”) and cementing, molding or sewing the bottom or sole of theshoes to the upper (“bottoming”). Modern footwear designs, particularlyathletic shoe designs, require numerous upper pieces and complicatedmanufacturing steps, leading to high labor costs. Additionally, a newpattern is required and the manufacturing process must be retooled forevery new design and style and for each desired shoe size. Evenmanufacturing processes that include molding techniques often involveother complicated manufacturing steps.

Proper footwear should complement the natural functionality of the foot,in part, by incorporating an upper that provides necessary comfort,stability, and other desired characteristics. The desired uppercharacteristics are often different for each footwear design, and mayoften be unique to the wearer. What is needed, therefore, is an improvedlabor-saving and time-saving method of manufacturing footwear that mayrequire reduced costs. Further, improved and effective manufacturingtechniques may provide for improved footwear customization capability.

BRIEF SUMMARY OF THE INVENTION

In one embodiment, a method for manufacturing an upper for an article offootwear includes: forming a contoured foam layer; forming a preliminaryupper by laminating an outer layer, an inner layer, and the foam layerintermediate to the outer layer and the inner layer; and molding thepreliminary upper to a shape having a contour to substantially fit atleast a portion of a foot to provide at least a portion of an upper foran article of footwear.

In another embodiment, a method for manufacturing an upper for anarticle of footwear includes: forming a foam layer; forming a laminatehaving an outer layer, an inner layer, and the foam layer intermediateto the outer layer and the inner layer; applying heat and pressure tothe laminate to form a medial portion of an upper shaped to fit a medialportion of a foot and a lateral portion of an upper shaped to fit alateral portion of the foot; and attaching the medial portion to thelateral portion to form a single piece upper for an article of footwear.

In yet another embodiment, a method for manufacturing an article offootwear includes: forming a single piece preliminary upper having anouter layer comprising an elastic polyurethane fiber, an inner layer,and a foam layer disposed between the outer layer and the inner layer;molding the preliminary upper to form a medial portion of an uppershaped to fit a medial portion of a foot and a lateral portion of anupper shaped to fit a lateral portion of the foot; attaching the lateralportion to the medial portion to form a single piece upper for anarticle of footwear; and attaching a sole to the upper.

In another embodiment, a method for manufacturing an article of footwearincludes: forming a contoured foam cushioning member; forming apreliminary upper by enveloping the foam cushioning member between anouter layer and an inner layer; and molding the preliminary upper to ashape having a contour to substantially fit at least a portion of afoot.

In still another embodiment, an upper for an article of footwearincludes a single piece laminate including a contoured foam cushioningmember, an inner layer, and an outer layer, wherein the foam cushioningmember is enveloped between the inner layer and the outer layer. A firstregion of the single piece laminate corresponds to a portion of alateral side of the foot and a second region of the single piecelaminate corresponds to a portion of a medial side of the foot. Theouter layer comprises an elastic material.

BRIEF DESCRIPTION OF THE DRAWINGS/FIGURES

The accompanying drawings, which are incorporated herein and form a partof the specification, illustrate the present invention and, togetherwith the description, further serve to explain the principles of theinvention and to enable a person skilled in the pertinent art to makeand use the invention.

FIG. 1 is a lateral side view of an article of footwear having a moldedupper according to an embodiment of the present invention.

FIG. 2 is a partial cross-sectional view of a molded upper according toan embodiment of the present invention.

FIG. 3 is a rear view of an article of footwear having a molded upperaccording to an embodiment of the present invention.

FIG. 4 is a top plan view of an article of footwear having a moldedupper according to an embodiment of the present invention.

FIG. 5 is a bottom plan view of a sole for an article of footwear havinga molded upper according to an embodiment of the present invention.

FIG. 6 is a partial cross-sectional view of a molded upper having acontinuous foam layer according to another embodiment of the presentinvention.

FIG. 7 is a perspective view of a molded upper for an article offootwear according to an embodiment of the present invention.

FIG. 8 is a bottom view of the molded upper of FIG. 7 according to anembodiment of the present invention.

FIG. 9 is a lateral side view of a molded upper for an article offootwear having a forefoot portion and a heel portion according to anembodiment of the present invention.

FIG. 10 is a bottom view of the molded upper of FIG. 9 according to anembodiment of the present invention.

FIG. 11 is a lateral side view of a molded upper for an article offootwear having a lateral side portion and a medial side portionaccording to an embodiment of the present invention.

FIG. 12 is a side view of a molded upper for an article of footwearhaving a forefoot portion and a heel portion according to an embodimentof the present invention.

FIG. 13 is a cross sectional view of a portion of the molded upper shownin FIG. 12 along the line 13-13 according to an embodiment of thepresent invention.

FIG. 14A is a cross sectional view of a portion of the molded uppershown in FIG. 12 according to an embodiment of the present invention.

FIG. 14B is a cross sectional view of a portion of the molded uppershown in FIG. 12 according to another embodiment of the presentinvention.

FIG. 14C is a cross sectional view of a portion of the molded uppershown in FIG. 12 according to another embodiment of the presentinvention.

FIG. 15 is a cross sectional view of a portion of the molded upper shownin FIG. 12 along the line 15-15 according to an embodiment of thepresent invention.

FIG. 16 is a laminate package of a portion of a molded upper for anarticle of footwear according to an embodiment of the present invention.

FIG. 17 is a perspective view of an article of footwear having a moldedupper portion of FIG. 14 according to an embodiment of the presentinvention.

FIG. 18 is a cross-sectional side view of an article of footwear havinga molded upper according to an embodiment of the present invention.

FIG. 19 is a lateral side view of an article of footwear having a moldedupper according to an embodiment of the present invention.

FIG. 20 is a partial interior view of the article of footwear of FIG. 19having a molded upper according to an embodiment of the presentinvention.

FIG. 21 is a schematic view of a mold for use in a method formanufacturing an upper for an article of footwear according to anembodiment of the present invention.

FIG. 22 is a partial schematic diagram of a molded upper according to anembodiment of the present invention.

FIG. 23 is a cross sectional view of a molded upper according to anembodiment of the present invention.

FIG. 24 is an exemplary flow diagram of a method for manufacturing anupper for an article of footwear according to an embodiment of thepresent invention.

FIG. 25 is an exemplary flow diagram of a method for manufacturing anupper for an article of footwear according to an embodiment of thepresent invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention will now be described in detail with reference toembodiments thereof as illustrated in the accompanying drawings, inwhich like reference numerals are used to indicate identical orfunctionally similar elements. References to “one embodiment”, “anembodiment”, “an example embodiment”, etc., indicate that the embodimentdescribed may include a particular feature, structure, orcharacteristic, but every embodiment may not necessarily include theparticular feature, structure, or characteristic. Moreover, such phrasesare not necessarily referring to the same embodiment. Further, when aparticular feature, structure, or characteristic is described inconnection with an embodiment, it is submitted that it is within theknowledge of one skilled in the art to affect such feature, stricture,or characteristic in connection with other embodiments whether or notexplicitly described.

The following examples are illustrative, but not limiting, of thepresent invention. Other suitable modifications and adaptations of thevariety of conditions and parameters normally encountered in the field,and which would be apparent to those skilled in the art, are within thespirit and scope of the invention.

Embodiments of the present invention include an upper 20 for an articleof footwear 10, and methods of making same. In some embodiments, thearticle of footwear 10 includes a sole 30 coupled to the upper 20. Withreference to FIGS. 1-5, for example, in one embodiment, the upper 20includes an outer layer 22 and an inner layer 23 enveloping a cushioningmember 24 to form a single piece laminate 21. Before the laminate 21undergoes molding according to embodiments of the present invention, thesingle piece laminate 21 may comprise a preliminary upper structure tobe molded to form all or a portion of the upper 20. During manufacture,the laminate 21 may be cut and molded to a shape having a contour tosubstantially fit at least a portion of a foot. In this manner, thefootwear 10 is provided using an improved labor-saving and customizablemethod of manufacturing footwear that may reduce costs.

In one embodiment, the laminate 21 may be molded by applying heat andpressure to the laminate 21 to form the upper 20 or one or more portionsof the upper 20. In one embodiment, the mold may be heated in order toheat and mold the laminate 21. In one embodiment, the laminate 21 may beheated (e.g., in a suitable oven) and then put into a mold forapplication of pressure to mold the laminate 21. Other moldingtechniques, also may be used to mold the single piece laminate 21 intothe upper 20 or one or more portions of the upper 20. For example, allor components of the laminate 21 may be provided as a liquid formulationthat foams into shape inside of a mold. According to some embodiments ofthe present invention, the laminate 21 may be molded using aspects ofcontour shape pressing techniques used in molding brassieres, such asthose described, for example in U.S. Pat. No. 6,805,610, the disclosureof which is incorporated herein by reference thereto.

In one embodiment, the outer layer 22 and/or the inner layer 23 comprisean elastic material such as, for example, Lycra®. In one embodiment, inparticular, one or both of the outer layer 22 and the inner layer 23 maycomprise a 4-way stretch Lycra®. In one embodiment, the outer layer 22and/or the inner layer 23 comprise about 40% Lycra content with anothermaterial, such as, for example nylon. In this manner, the outer layer 22and the inner layer 23 provide a single piece laminate 21 structure thatis lightweight and flexible. Other suitable materials, including, butnot limited to, elastic polyurethane fiber, elastane, a 2-way stretchmaterial, a 4-way stretch material, and polyamide nylon, may be used. Inone embodiment, the material used for the inner layer 23 and/or outerlayer 22 may comprise material similar to that used for intimateapparel, such as, for example, brassieres, and the like. In oneembodiment, the outer layer 22 and the inner layer 23 are made of thesame material. In another embodiment, the outer layer 22 and the innerlayer 23 are made of different materials. In one embodiment, one or morelayers of the laminate 21, including one or more of the outer layer 22and the inner layer 23, comprise materials having suitablebreathability, wicking characteristics, waterproof characteristics,and/or non-abrasive characteristics. In one embodiment, one or both ofthe outer layer 22 and the inner layer 23 may comprise a well knittingfabric having moisture management supplied by Best Pacific Textile Ltd.having an article no. PL-995MFX1. In one embodiment, the outer layer 22and/or the inner layer 23 may comprise a material having high elongationcharacteristics (e.g., about 500%-about 700%), low elastic modulus(e.g., about 200% elongation, about 0.04 to about 0.12 g/denier), and/orhigh elastic recovery rate (e.g., about 200% elongation, 95%-99%).

In one embodiment, the cushioning member 24 comprises a contoured foam.The cushioning member 24 may be contoured to provide desired cushioningcharacteristics. In this manner, the cushioning member 24 may becontoured to a shape that substantially fits at least a portion of thefoot of the wearer. For example, as shown in FIG. 3, the cushioningmember 24 may be contoured to a shape that cushions a heel portion ofthe foot. in other embodiments, the cushioning member 24 may becontoured to a shape that cushions an upper portion of the footcorresponding to a vamp or tongue portion of the footwear 10, a quarterpanel, a collar, or any other desired portion of the upper. In someembodiments, cushioning member 24 may be contoured to a shape foraesthetic purposes.

With reference to FIG. 23, in one embodiment, the cushioning member 24may be precisely contoured such that it has varying thickness to fit thedesired area between outer layer 22 and inner layer 23. In someembodiments, cushioning member 24 may have asymmetrical cross-sections.The cushioning member 24 may be contoured using skiving, molding, heatmolding, pressure molding, blow molding, or other suitable techniques.However, unlike conventional foam pieces used in footwear to providecushioning or contour, including die-cut foam pieces, the cushioningmember 24 is pre-shaped before inclusion in the laminate 21 for moldingand is provided to have a uniform presence within the laminate 21. Forexample, the upper 20 having a cushioning member 24 according toembodiments of the present invention may be provided without any gapsbetween the cushioning member 24 and the outer layer 22 and/or innerlayer 23. For example, as shown in FIG. 23, the cushioning member 24tapers to the point of intersection between the outer layer 22 and innerlayer 23 such that there are no gaps between the cushioning member andthe layers. In contrast, in conventional uppers a die-cut block of foammay be placed in a similar area, causing gaps between the foam and theinner and outer layers at the point of intersection. In addition, insome embodiments, unlike conventional foam pieces which may becompressed or “wedged” to fit into an area between an inner layer andouter layer of the conventional shoe, the cushioning member 24 is notcompressed to fit within an area of the upper but rather is preciselycontoured to fit the area. Because the cushioning member 24 is notcompressed, the laminate 21 may be provided with a cushioning member 24having a substantially uniform density throughout. In this manner, thecushioning member 24 may more comfortably fit to a portion of thewearer's foot, and may provide the desired cushioning, feel, andaesthetic characteristics

Suitable material for cushioning member 24 may include, but is notlimited to, foam, thermoplastic polyurethane (TPU), and thermoplasticrubber (TPR). In one embodiment, cushioning member 24 may comprise ahigh grade memory foam. When cushioning member 24 is a foam, the foammay be, for example, ethyl vinyl acetate (EVA) based or polyurethane(PU) based and the foam may be an open-cell foam or a closed-cell foam.In other embodiments, cushioning member 24 may comprise elastomers,thermoplastic elastomers (TPE), polyethylene (PE), foam-like plastic(e.g., Pebax® foam or Hytrel® foam) and gel-like plastics.

Upper 20 may be used in conjunction with a variety of soles 30, in oneembodiment, the sole 30 may include a plurality of projections 31 toprovide the desired cushioning and ride characteristics for the footwear10, as shown, for example, in FIG. 5, and as described, for example, inU.S. Patent Application Publication No. 2012/0073160, entitled “SoleWith Projections and Article of Footwear” and published on Mar. 29,2012, the disclosure of which is incorporated herein in its entirety byreference thereto. In one embodiment, the sole 30 may undulate to definegaps in its top and bottom surface so as to be substantially sinusoidal,as described, for example, in U.S. Patent Application Publication No.2011/0016749, entitled “Article of Footwear and Methods of Making Same”and published on Jan. 27, 2011, the disclosure of which is incorporatedherein in its entirety by reference thereto.

In one embodiment, the sole 30 may comprise a resilient material suchthat the sole provides a flexible ride and desired cushioning to thewearer. In one embodiment, the sole 30 comprises foam, such as, forexample, ethyl vinyl acetate (EVA) foam or polyurethane (PU) foam, andthe foam may be an open-cell foam or a closed-cell foam. In otherembodiments, sole 30 may comprise elastomers, thermoplastic elastomers(TPE), foam-like plastic (e.g., Pebax® foam or Hytre® foam), gel-likeplastics, thermoplastic rubber (TPR), and combinations thereof in oneembodiment, the sole 30 may include a molded thermoplastic componentsuch as, for example, an injection molded TPU component. In oneembodiment of the present invention, an insole and/or sockliner may alsobe included within the footwear 10. In some embodiments, the sole 30 mayinclude an insole and/or sockliner. In some embodiments, a plate may bedisposed between the sole 30 and the wearer's foot. The plate maycomprise, for example, compressed cellulose, plastic, TPU, and the like.Sole 30 may be attached to the upper 20 using adhesive bonding,stitching, welding, or other suitable techniques.

In one embodiment of the present invention, an outsole (not shown) maybe disposed on all or a portion of the bottom surface of the sole 30.The outsole may comprise a wear-resistant material. For example, theoutsole can include synthetic or natural rubber, polyurethane (e.g.,thermoplastic polyurethane (TPU)), foam (e.g., a wear-resistant foam),or a combination thereof. In some embodiments, the sole 30 and theoutsole may be formed of the same or different material. In oneembodiment, they may be molded together as a unitary structure.

As shown, for example, in FIGS. 2 and 6, in one embodiment laminate 21includes the outer layer 22 and the inner layer 23 enveloping a firstfoam layer, the cushioning member 24. In one embodiment, the laminate 21may further include a foam sheet 25. In one embodiment, the foam sheet25 is disposed intermediate to the cushioning member 24 and the outerlayer 22. In another embodiment, the foam sheet 25 may be disposedintermediate to the cushioning member 24 and the inner layer 23. Thefoam sheet 25 may be a continuous layer that extends over all or aportion of the surface of the laminate 21. In one embodiment, thecushioning member 24 may have a thickness in the range of about 0.5 mmto about 20 mm. The foam sheet 25 may have a thickness in the range ofabout 0.5 mm to about 1.5 mm. The foam sheet 25 may provide a smoothingeffect to the upper 20 so as to smooth the transition between an area ofthe upper 20 having the cushioning member 24 to an area of the upperhaving no cushioning member. In some embodiments, this may provide adesired shape, smoothness, softness, and cushioning property to theupper 20. In one embodiment, the foam sheet may provide support to thewearer during use. In one embodiment, the foam sheet 25 may comprise apermeable membrane such that vapor may be released from the interior ofthe upper 20 while reducing or preventing moisture from entering theinterior of the upper 20. In one embodiment, the foam sheet 25 maycomprise a anti-microbial material.

In one embodiment, the foam sheet 25 may be attached to an adjacentlayer of the laminate 21 using a urethane spray or other suitableadhesive. The adhesive preferably does not create stiffness differencesbetween areas of the upper 20. The depiction of the laminate structurein FIG. 6 is intended to be illustrative only and not limiting. The sizeand shape of the outer layer 22, the inner layer 23, the cushioningmember 24, and the foam sheet 25 may vary to provide the desiredcharacteristics of the upper 20. In some embodiments, one or more ofthese elements may not be provided in the laminate 21. Suitable materialfor the foam sheet 25 may include, but is not limited to, foam andthermoplastic polyurethane. The foam may be, for example, ethyl vinylacetate (EVA) based or polyurethane (PU) based and the foam may be anopen-cell foam or a closed-cell foam.

In one embodiment, the laminate 21 is molded to a shape having a contourto substantially fit at least a portion of a foot. In one embodiment,the laminate 21 may include a first portion 210 to be molded to a shapehaving a contour to substantially fit a first portion of a foot and asecond portion 211 to be molded to a shape having a contour tosubstantially fit a second portion of a foot. For example, withreference to FIGS. 7 and 8, the laminate 21 may include a lateralportion 210 to be molded to a shape having a contour to substantiallyfit a lateral portion of a foot and a medial portion 211 to be molded toa shape having a contour to substantially fit a medial portion of afoot. As shown in FIG. 7, in one embodiment the lateral portion 210 maysubstantially cover the lateral side of the foot from the heel region102 to the toe region 106, and the medial portion 211 may substantiallycover the medial side of the foot from the heel region 102 to the toeregion 106. In other embodiments, the lateral portion 210 and/or themedial portion 211 may cover only a portion of the respective side ofthe foot. For example, the lateral portion 210 may cover only the heelregion 102 of the lateral side of the foot, or the medial portion 211may cover only from the heel region 102 to the midfoot region 104 of themedial side of the foot.

In another embodiment, with reference to FIG. 9, for example, thelaminate 21 may include a forward portion 212 and a rearward portion213. For example, the forward portion 212 of the laminate 21 may bemolded to a shape having a contour to substantially fit a forwardportion of the foot extending from the midfoot region 104 to the toeregion 106 on both the medial and lateral sides of the foot, and therearward portion 213 may be molded to a shape having a contour tosubstantially fit a rearward portion of the foot extending from themidfoot region 104 to the heel region 102 on both the medial and lateralsides of the foot. The size, shape, and location of the first portion210 and the second portion 211 may vary as needed.

In one embodiment, the first portion 210 and the second portion 211 maybe molded from the same laminate 21 such that both portions share atleast one continuous layer of the laminate 21 in common (e.g., the outerlayer 22, the inner layer 23, the cushioning member 24, and/or the foamsheet 25, where included). For example, with reference to FIG. 11, thelaminate 21 may include a lateral portion 210 to be molded to a shapehaving a contour to substantially fit a lateral portion of a foot and amedial portion 211 to he molded to a shape having a contour tosubstantially fit a medial portion of a foot, wherein both portionsshare a continuous outer layer 22 (shown), inner layer 23, andcushioning member 24 in common. In this manner, the lateral portion 210and the medial portion share a common border in the heel region 102 ofthe upper 20, as shown, in some embodiments, a first portion 210 and asecond portion 211 molded from the same laminate 21 may share a commonborder along another portion of the upper 20, such as, for example,along the length of the bottom of the upper. In other embodiments, asingle portion 210 may be molded from a laminate 21. In one embodiment,a first portion 210 may be molded from a first laminate 21, and a secondportion 211 may be molded from a second laminate 21 such that the firstportion 210 and the second portion 211 do not share at least onecontinuous layer of laminate and do not share a common border.

In embodiments in which one or more laminates 21 are molded to form afirst portion 210 and a second portion 211, the first portion 210 andthe second portion 211 may be attached, after the one or more laminates21 are molded, to form a single piece upper 20 for an article offootwear. The first portion 210 and the second portion 211 may beattached by one or more of adhesive, stitching, adhesive seam tape, RFwelding, ultrasonic bonding, and other suitable attachment means. In oneembodiment, adhesive seam tape used may comprise thermoplastic seam tapecomprising a material selected form, the group consisting ofpolyurethane, polyamide, polyester, nylon, polyolefin, vinyl,polypropylene, thermoplastic urethane, tricot, acrylic, and PVC. Anexample of suitable seam tape for use in embodiments of the presentinvention is produced by Bemis Associates, Inc. of Shirley Mass.

As shown in FIGS. 7 and 8, for example, the first portion 210 and thesecond portion 211 may be attached along a longitudinal seam 214 alongthe length of the bottom of the upper 20 from the heel region 102 to thetoe region 106. In one embodiment, as shown, for example, in FIG. 9, theseam 214 may extend from a bottom edge 26 of the upper 20 along aportion of midfoot region 104 of the upper 20. In one embodiment, theseam 214 may extend along only a portion of the Upper 20 so as to createan opening (not shown) to allow venting of air into or out of theinterior of the upper 20.

In one embodiment, the first portion 210 and the second portion 211 maynot comprise an entire upper 20 When attached. As shown for example, inFIG. 10, the forward portion 212 and the rearward portion 213, whenattached, may not include an upper bottom 27. A bottom 27 may beattached, by strobel stitching or other suitable means, to the firstportion 210 and the second portion 211 so as to provide the upper 20.

With reference to FIGS. 12-15, an upper 20 having a forward portion 212and a rearward portion 213 adapted to be attached along a seam 214 willnow be described. In one embodiment, as shown, for example, in FIG. 14A,the forward portion 212 may be formed with a perimeter tab 217 extendingfrom the laminate 21 and the rearward portion 213 may he formed with anopening 218 between the outer layer 22 and the inner layer 23 forreceiving the perimeter tab 217. The perimeter tab 217 may be attachedto the rearward portion 213 with adhesive (as shown), stitching,adhesive seam tape, RF welding, ultrasonic bonding, and/or othersuitable attachment techniques. In one embodiment, as shown, forexample, in FIG. 14C, the perimeter tab 217 may be formed by therearward portion 212 and the opening 218 between the outer layer 22 andthe inner layer 23 may be formed by the forward portion 212. In oneembodiment, as shown, for example, in FIG. 14B, both the forward portion212 and the rearward portion 213 may be formed with a perimeter tab 217extending from the laminate 21. The forward and rearward perimeter tabs217 may be overlapped and then attached. In one embodiment, the forwardportion 212, and the rearward portion 213 may be attached by a buttseam.

In one embodiment, as shown, for example, in FIGS. 15 and 22, thelaminate 21 may further include one or more reinforcing layers 28. Thereinforcing layer 28 may provide desired stiffness to the upper 20 at adesired location. For example, the reinforcing layer 28 may be used inrearward portion 213 approximate the lacing eyelets to provide desiredstiffness to this area to facilitate lacing of the upper 20. Thereinforcing layer 28 may include a series of holes (not shown) tocoincide with the eyelets. In one embodiment, the reinforcing layer 28may comprise a stretchable material, including, but not limited to,elasticated banding material (e.g., Gore®), elasticated webbing; knittedmaterial (e.g., circular knitted material), and other suitablestretchable material. In another embodiment, the reinforcing layer 28may comprise a non-stretchable material, including, but not limited to,non-woven or woven textile material. In one embodiment, the reinforcinglayer 28 may comprise a mesh layer. In some embodiments, both astretchable reinforcing layer 28 and a non-stretchable reinforcing layer28 may be used. For example, from outermost layer to innermost layer thelaminate 21 may include an outer layer 22 (comprising, for example,Lycra®), a non-stretchable reinforcing layer 28, a foam sheet 25, a foamcushioning member 24, a stretchable reinforcing layer 28, and an innerlayer 23 (comprising, for example, Lycra®).

As discussed, the laminate 21 is molded to a shape having a contour tosubstantially fit at least a portion of a foot. In one embodiment, asshown, for example, in FIGS. 16 and 17, the laminate 21 may include afirst portion 210 to be molded to a shape having a contour tosubstantially fit a heel collar portion 215 of the upper 20. Thelaminate 21 may be molded to include a hinge 216. The hinge 216 maycomprise a portion of the laminate 21 without a cushioning member 24that is adjacent to areas of the laminate having a cushioning member 24.The hinge 216 may substantially align with a vertical segment at theheel of the foot. In this manner, the heel collar portion 215 may have aclamshell-like structure that may facilitate the portion substantiallyfitting the contours of the heel of the foot. In one embodiment, asshown, for example, in FIG. 17, the heel collar portion 215 may includea thick cushioning member 24 (relative to cushioning members 24 providedin other areas of the upper 20) so as to provide an enlarged heel collarportion 215.

FIG. 18 is a partial cross-sectional view of a molded upper 20 accordingto an embodiment of the present invention. As discussed above, the sizeand shape of the cushioning layer 24 may vary depending on the desiredcharacteristics of the upper 20. In one embodiment, the cushioning layer24 may be contoured for anatomical purposes. In one embodiment, thecushioning layer 24 may be contoured to create a massaging effect on thewearer. In one embodiment, all or a portion of the cushioning layer maybe contoured for extra comfort. In one embodiment, the upper 20 may bemolded to include an integral a lining or footbed, as shown. In thisembodiment, the shoe 10 may be provided without a sock liner. In thismanner, the molded upper 20 may comprise a “bootie” with comfort andfeel of the laminate 21 around the entire foot.

In one embodiment, the laminate 21 may initially comprise the innerlayer 23 and the cushioning member 24 (with or without the foam sheet25) and the outer layer 22 may be added after the preliminary upperstructure has been molded. The outer layer 22 may be added using similara molding process. In some embodiments, this may provide an efficientmanufacturing process whereby the outer layer 22 may be customizable.For example, different color or pattern outer layers 22 may be used withthe same underlying inner layer 23 and cushioning member laminate. Inthis manner, in one embodiment a modular upper 20 may be provided with astandard interior of the upper 20 (e.g., inner layer 23) and flexibilityin styling the exterior of the upper 20 (e.g., outer layer 22).

With reference to FIGS. 19 and 20, a molded upper 20 according to anembodiment of the present invention includes a laminate 21 having aninner layer 23, an outer layer 22, and a cushioning member 24 disposedbetween the inner 23 and outer 22 layers. As discussed above, the sizeand shape of the cushioning layer 24 may vary depending on the desiredcharacteristics of the upper 20. In one embodiment, as shown for examplein FIGS. 19 and 20, the cushioning layer 24 may include a plurality ofribs 29 that extend from a midfoot portion of the upper on the lateralside around the heel portion of the upper to the medial side of theupper. The cushioning layer 24 may further include a heel collar portion215 that extends about the interior collar of the heel portion of theupper.

With reference to FIG. 21, in one embodiment a mold 300 for molding anupper 20 according to embodiments of the present invention includes alower plate 310 and an upper plate 320. The lower plate may include athree-dimensional profile of an upper 20 having a first portion 312 anda second portion 314, and the upper plate includes a correspondingrelief or cavity (not shown) for receiving the profile 311 during themolding process.

With reference to FIG. 24, a method 400 for manufacturing an upper foran article of footwear according to embodiments of the present inventionwill now be described. In one embodiment, the method includes steps 402,404, and 406, and may include additional or fewer steps. In step 402, afoam cushioning member 24 is formed. In step 404, a preliminary upper 21is formed by enveloping the foam cushioning member 24 between an outerlayer 22 and an inner layer 22. In step 406, the preliminary upper 21 ismolded to a shape having a contour to substantially fit at least aportion of the foot.

With reference to FIG. 25, a method 500 for manufacturing an upper foran article of footwear according to embodiments of the present inventionwill now be described. The method includes steps 501, 502, 503, and 504,and may include additional or fewer steps. In step 501, a foam layer 24is formed. In step 502, a laminate 21 is formed having the foam layer 24in between an outer layer 22 and an inner layer 23. In step 503, heatand pressure is applied to the laminate 21 to form a first portion of anupper shaped to fit a first portion of a foot and a second portion of anupper shaped to fit a second portion of the foot. In step 504, the firstportion of the upper is attached to the second portion of the upper toform a single piece upper for an article of footwear.

The foregoing description of the specific embodiments will so fullyreveal the general nature of the invention that others can, by applyingknowledge within the skill of the art, readily modify and/or adapt forvarious applications such specific embodiments, without undueexperimentation, without departing from the general concept of thepresent invention. Therefore, such adaptations and modifications areintended to be within the meaning and range of equivalents of thedisclosed embodiments, based on the teaching and guidance presentedherein. It is to be understood that the phraseology or terminologyherein is for the purpose of description and not of limitation, suchthat the terminology or phraseology of the present specification is tobe interpreted by the skilled artisan in light of the teachings andguidance.

The breadth and scope of the present invention should not be limited byany of the above-described exemplary embodiments, but should be definedonly in accordance with the following claims and their equivalents.

1. A method for manufacturing an upper for an article of footwear,comprising: forming a contoured foam layer; forming a preliminary upperby laminating an outer layer, an inner layer, and the foam layerintermediate to the outer layer and the inner layer; and molding thepreliminary upper to a shape having a contour to substantially fit atleast a portion of a foot to provide at least a portion of an upper foran article of footwear.
 2. The method of claim 1, wherein thepreliminary upper is molded to a shape having a contour to fit a heelportion of the foot.
 3. The method of claim 1, wherein the preliminaryupper is molded to a shape having a contour to fit a forefoot portion ofthe foot and a heel portion of the foot.
 4. The method of claim 1,wherein the preliminary upper is molded to a shape having a contour tofit a forefoot portion of the foot, a heel portion of the foot, and anintermediate portion of the foot between the forefoot portion and theheel portion.
 5. The method of claim 1, wherein the preliminary upper ismolded to form a single piece upper having a medial portion, a lateralportion, and a footbed portion.
 6. The method of claim 1, wherein theouter layer comprises an elastic material.
 7. The method of clam 1,wherein outer layer comprises an elastic polyurethane fiber.
 8. Themethod of claim 1, wherein the outer layer comprises elastane.
 9. Themethod of claim 1, wherein the outer layer and the inner layer comprisean elastic material.
 10. The method of claim 1, wherein the outer layerand the inner layer comprise the same material.
 11. The method of claim1, wherein the step of molding the preliminary upper includes applyingheat and pressure to the preliminary upper.
 12. The method of claim 1,wherein the foam layer is formed to a shape having a contour to fit aheel portion of a foot.
 13. The method of claim 1, wherein thepreliminary upper is substantially flat before molding.
 14. The methodof claim 1, wherein the foam layer has a variable thickness.
 15. Amethod for manufacturing an upper for an article of footwear,comprising: forming a foam layer; forming a laminate having an outerlayer, an inner layer, and the foam layer intermediate to the outerlayer and the inner layer; applying heat and pressure to the laminate toform a medial portion of an upper shaped to fit a medial portion of afoot and a lateral portion of an upper shaped to fit a lateral portionof the foot; and attaching the medial portion to the lateral portion toform a single piece upper for an article of footwear.
 16. The method ofclaim 15, wherein the outer layer and the inner layer comprise anelastic polyurethane fiber.
 17. The method of claim 15, furthercomprising attaching the medial portion to the lateral portion along aseam extending along the length of the upper.
 18. The method of claim15, wherein the laminate is a single piece laminate and the medialportion and the lateral portion are integral portions of the singlepiece laminate,
 19. The method of claim 15, wherein the laminate issubstantially flat before applying heat and pressure during molding. 20.The method of claim 15, wherein the foam layer has a variable thickness.21. The method of claim 15, wherein the step of applying heat andpressure includes heating the laminate and placing the heated laminateinto a mold.
 22. A method for manufacturing an article of footwear,comprising: forming a single piece preliminary upper having an outerlayer comprising an elastic polyurethane fiber, an inner layer, and afoam layer disposed between the outer layer and the inner layer; moldingthe preliminary upper to form a medial portion of an upper shaped to fita medial portion of a foot and a lateral portion of an upper shaped tofit a lateral portion of the foot; attaching the lateral portion to themedial portion to form a single piece upper for an article of footwear;and attaching a sole to the upper.
 23. A method for manufacturing anarticle of footwear, comprising the steps of: forming a contoured foamcushioning member; forming a preliminary upper by enveloping the foamcushioning member between an outer layer and an inner layer; and moldingthe preliminary upper to a shape having a contour to substantially fitat least a portion of a foot.
 24. The method of claim 23 wherein themolding step includes placing the preliminary upper on a mold andapplying heat and pressure, wherein a first region of the moldcorresponds to a portion of a medial side of a foot and a second regionof the mold corresponds to a portion of a lateral side of the foot. 25.The method of claim 23 wherein the molding step includes placing thepreliminary Upper on a mold having a shape corresponding to a medialside of a foot and applying heat and pressure to the preliminary upper.26. The method of claim 23 wherein the molding step includes placing thepreliminary upper on a mold having a shape corresponding to a lateralside of a foot and applying heat and pressure to the preliminary upper.27. The method of claim 23 wherein the foam cushioning member is formedby molding.
 28. An upper for an article of footwear, comprising: asingle piece laminate including a contoured foam cushioning member, aninner layer, and an outer layer, wherein the foam cushioning member isenveloped between the inner layer and the outer layer, wherein a firstregion of the single piece laminate corresponds to a portion of alateral side of the foot and a second region of the single piecelaminate corresponds to a portion of a medial side of the foot, andwherein the outer layer comprises an elastic material.
 29. An article offootwear comprising: a footwear upper formed of one or more pieces, eachpiece comprising one or more layers; a footwear lower attached to thefootwear upper to provide a sole supporting member to the article offootwear; wherein the one or more pieces used to form the footwear upperare molded into a three dimensional configuration.
 30. An article offootwear according to claim 29, wherein at least one of the piecesforming the footwear upper is multilayered.
 31. An article of footwearaccording to claim 30, wherein the multilayered piece comprises; anouter layer; a middle layer; and an inner layer.
 32. An article offootwear according to claim 29, wherein the footwear upper comprises asingle layer.
 33. An article of footwear according to claim 29, whereinthe one or more pieces forming the footwear upper are joined so as toprovide a substantially seamless inner surface.
 34. An article offootwear according to claim 29, wherein the footwear upper is formedfrom a single piece.
 35. An article of footwear according to claim 34,wherein the footwear upper is formed from a single piece comprising anouter fabric layer, a middle foam layer and an inner fabric layer. 36.An article of footwear according to claim 30, wherein the footwear upperincludes padding positioned at one or more anatomically determinedpositions to provide enhanced cushioning, reinforcement or support. 37.An article of footwear according to claim 29, wherein the footwear upperincludes an upper opening to receive a wearer's foot, the upper openinghaving an upper edge, and a lower opening having a lower edge to whichthe footwear lower is attached to provide a sole supporting member,wherein the upper edge is finished to provide a seamless edge.
 38. Anarticle of footwear according to claim 29, wherein one or moredecorative and/or structural features are added to an outer surface ofthe footwear upper by use of a heat sealable film along at least anouter periphery of the decorative feature.
 39. An article of footwearaccording to claim 38, wherein structural features in the form of eyesfor receiving shoe laces are attached to the footwear upper using a heatsealable film.
 40. An article of footwear according to claim 29, whereinthe molding involves the application of heat and pressure.
 41. A methodfor forming an article of footwear, the method comprising the followingsteps: molding one or more pieces for forming a footwear upper into asuitable three dimensional configuration; forming the footwear upperfrom the one or more pieces, each piece comprising one or more layers;and attaching a footwear lower to the footwear upper to provide a solesupporting member to the article of footwear.
 42. A method for formingan article of footwear according to claim 41, wherein the step ofmolding one or more pieces for forming a footwear upper into a suitablethree dimensional configuration includes placing the piece into a heatpress molding apparatus including complementary shaped first and secondmolding portions, wherein the first molding portion is configured toreceive a complementary shaped second molding portion so that the pieceis formed into a three dimensional configuration there between.
 43. Amethod for forming an article of footwear according to claim 41, whereinthe footwear upper is formed from more than one piece and each piece isjoined to its adjacent piece by ultrasonic welding.
 44. (canceled) 45.(canceled)
 46. A method for forming an article of footwear according toclaim 41, wherein the molding involves the application of heat andpressure.
 47. A method for forming an article of footwear according toclaim 41, wherein the molding of each of the one or more pieces forforming a footwear upper into a suitable three dimensional configurationcomprises the steps of: providing a first sheet of material which is tobe an outer layer of the footwear upper, providing a second sheet ofmaterial which is to be an inner layer of the footwear upper, providingbetween the first and second sheets of material a sheet of foam which isto be a middle layer of the footwear upper, and molding together thefirst and second sheets of material and the sheet of foam to laminatethe sheets.
 48. A method for forming an article of footwear according toclaim 47, wherein the first and second sheets of material each comprisesa layer of fabric.
 49. A inner lining for an article of footwear,comprising: a footwear liner formed of one or more pieces, each piececomprising one or more layers, the footwear liner configured to receivea wearer's foot; wherein the one or more pieces used to form thefootwear liner are molded into a three dimensional configuration.
 50. Aninner lining for an article of footwear according to claim 49, whereinthe inner lining is placed within and fastened to a footwear upper toform an article of footwear.
 51. An inner lining for an article offootwear according to claim 50, wherein the inner lining is removablyfastened to the footwear upper.
 52. An inner lining for an article offootwear according to claim 49, wherein the footwear liner is formedfrom one piece, the one piece being molded into a three dimensionalconfiguration using a heat press molding apparatus,
 53. An inner liningfor an article of footwear according to claim 52, wherein the heat pressmolding apparatus includes complementary shaped first and second moldingportions, wherein the first molding portion is configured to receive acomplementary shaped second molding portion so that the footwear lineris formed into a three dimensional configuration there between.
 54. Aninner lining for an article of footwear according to claim 49, whereinthe footwear liner is formed from two pieces, each piece being moldedinto a three dimensional configuration using a heat press moldingapparatus.
 55. An inner lining for an article of footwear according toclaim 54, wherein one of the two pieces is independently molded into aleft side piece and the other one of the two pieces is independentlymolded into a right side piece, such that the molded left side piece andthe molded right side piece can be joined together to form the footwearliner configured to receive a wearer's foot.
 56. An inner lining for anarticle of footwear according to claim 55, wherein the molded left sidepiece and the molded right side piece are joined together using nonstitching means.
 57. An inner lining for an article of footwearaccording to claim 55, wherein the molded left side piece and the moldedright side piece are joined together by ultrasonic welding.
 58. Anarticle of footwear including an inner lining, comprising: a footwearupper; a footwear liner formed of one or more pieces, each piececomprising one or more layers, the footwear liner configured to receivea wearer's foot; and a footwear lower attached to the footwear upper toprovide a sole supporting member to the article of footwear; wherein theone or more pieces used to form the footwear liner are molded into athree dimensional configuration.
 59. An article of footwear comprising:a footwear upper formed of one or more pieces, each piece comprising oneor more layers; a footwear lower attached to the footwear upper toprovide a sole supporting member to the article of footwear; wherein theone or more pieces used to form the footwear upper are molded into athree dimensional configuration, each of the one or more pieces used toform the footwear upper having no seams away from the edges of thepiece.
 60. An inner lining for an article of footwear, comprising: afootwear liner formed of one or more pieces, each piece comprising oneor more layers, the footwear liner configured to receive a wearer'sfoot; wherein the one or more pieces used to form the footwear liner aremolded into a three dimensional configuration, each of the one or morepieces used to form an upper part of the footwear liner having no seamsaway from the edges of the piece.
 61. An article of footwear includingan inner lining, comprising: a footwear upper; a footwear liner formedof one or more pieces, each piece comprising one or more layers, thefootwear liner configured to receive a wearer's foot; and a footwearlower attached to the footwear upper to provide a sole supporting memberto the article of footwear; wherein the one or more pieces used to formthe footwear liner are molded into a three dimensional configuration,the one or more pieces used to form the footwear liner including twopieces used to form an upper part of the footwear liner.